Process of making woven articles comprising water-dispersible multicomponent fibers

Abstract

Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispersible sulfopolyester having a Tg of at least 57° C. and a water non-dispersible polymer. The multicomponent fibers may be used to produce microdenier fibers. Fibrous articles may be produced from the water-dispersible fibers, multicomponent fibers, and microdenier fibers. The fibrous articles include water-dispersible and microdenier nonwoven webs, fabrics, and multilayered articles such as wipes, gauze, tissue, diapers, panty liners, sanitary napkins, bandages, and surgical dressings. Also disclosed is a process for water-dispersible fibers, nonwoven fabrics, and microdenier webs. The fibers and fibrous articles have further applications in flushable personal care and cleaning products, disposable protective outerwear, and laminating binders.

1. A process for producing a woven fabric comprising:
 (A) producing at least one multicomponent fiber having a shaped cross section by a process which comprises spinning at least one water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57° C. and at least one water-nondispersible polymer immiscible with said sulfopolyester into said multicomponent fiber, said sulfopolyester comprising: 
 (i) residues of one or more dicarboxylic acids; 
 (ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof; 
 (iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure
   H—(OCH 2 —CH 2 ) n —OH
 
 wherein n is an integer in the range of 2 to about 500; and 
 
 (iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof; 
 wherein said multicomponent fiber comprises a plurality of segments comprising said water-nondispersible polymers immiscible with said sulfopolyester, wherein said segments are substantially isolated from each other by said sulfopolyester intervening between said segments; 
 (B) quenching said multicomponent fiber thereby solidifying said multicomponent fiber; 
 (C) applying at least one finish to said multicomponent fiber; 
 (D) drawing said multicomponent fiber; 
 (E) optionally texturizing or crimping said multicomponent fiber; and 
 (F) knitting or weaving the multicomponent fiber of Step D or Step E to form said woven fabric. 
 
     
     
       2. The process according to  claim 1  wherein said sulfopolyester comprises:
 (i) about 50 to about 96 mole % of one or more residues of isophthalic acid or terephthalic acid, based on the total acid residues; 
 (ii) about 4 to about 30 mole %, based on the total acid residues, of a residue of sodiosulfoisophthalic acid; 
 (iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure
   H—(OCH 2 —CH 2 ) n —OH
 
 wherein n is an integer in the range of 2 to about 500; and 
 
 (iv) 0 to about 20 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof. 
 
     
     
       3. The process according to  claim 1  wherein said multicomponent fiber contains less than 10 weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber. 
     
     
       4. The process according to  claim 3  wherein said shaped cross section is an islands-in-the-sea, segmented pie or side by side configuration. 
     
     
       5. The process according to  claim 1  wherein said finish further comprises at least one additive. 
     
     
       6. The process according to  claim 5  wherein said additive is at least one selected from the group consisting of emulsifiers, antistatics, antimicrobials, antifoams, lubricants, thermostabilizers, and UV stabilizers. 
     
     
       7. The process according to  claim 1  further comprising contacting said multicomponent fiber contained in said woven fabric with water to remove said sulfopolyester. 
     
     
       8. The process of  claim 7  wherein said contacting with water is conducted at a temperature in the range of about 25° C. to about 100° C. 
     
     
       9. The process of  claim 8  wherein said contacting with water is conducted at a temperature in the range of about 50° C. to about 80° C. 
     
     
       10. The process of  claim 1  wherein said contacting with water is conducted for a time ranging from about 10 to about 600 seconds. 
     
     
       11. The process according to  claim 1  wherein said water-nondispersible polymer is at least one selected from the group consisting of polyolefins, polyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, polyvinyl chlorides, cellulose esters, and combinations thereof. 
     
     
       12. The process according to  claim 1  wherein said water-nondispersible polymer is biodistintegratable as determined by DIN Standard 54900 or biodegradable as determined by ASTM Standard Method, D6340-98. 
     
     
       13. The process according to  claim 1  wherein said water-nondispersible polymer is an aliphatic-aromatic polyester.